Vertical Roller Mill

VERTICAL ROLLER MILLS
Confederation of Indian Industry
Vertical Roller Mills (VRM)

An advancement over ball mill Roller mill Grinding by Compression Rollers / Balls on ring Presently for Raw meal, Coal & Cement More Energy efficient
VRM - Features
VRM Drive - 40% of ball mill Dry moisture up to 15 % More compact & Less space Fan Power consumption - High Separator - Integral Part of Mill
Features of VRM
Energy Efficient Grinding System
Mill drive 40% less consumption
Most suited for drying upto 15% moisture More compact & occupies less space More amenable for Controls
Comparison of Ball Mill & VRM

Ball Mill VRM
Moisture (%) Mill Drive (units/ton) Fan + separator Total
3.0 14.0 1.9 15.9
7.0 14.0 5.0 19.0
3.0 6.5 7.5 14.0
7.0 6.5 7.5 14.0
Ideal choice for high moisture material

ENERGY SAVING IN VRMs

Fine tuning of louvres Mechanical Recirculation system High efficiency classifier High Level Control system
Install Variable Area Louvre Ring

Air flow inside VRM not uniform Material leaves in a definite pattern around table Max. material behind and in front of each roller

Uniform area louvre ring
Uniform gas system Uneven bed of material Gas prefers path of least resistance Higher gas flow rates essential

Variable area louvre ring
Larger area at points of larger concentration Gas flow directed to material Potential open area higher Lower Pr.Drop and lower gas flow Reduced fan power consumption

Presently fixed area louvre ring Pr.Drop across mill 870MM WG Flow thro mill 3,40,000 M3 / HR Mill output 155 TPH Recommended to install variable area louvre

Pr. Drop across mill 820 MM WG Flow thro mill 3,10,000 M3/HR Mill output 155 TPH Annual savings Rs 9.2 Lakhs
Re Ga s Re jec ts
jec
ts
Area 1.132 m2 B A A B C D Velocity 83 MPS E F F E D

1 Roller
D E F F E D C B A A B C D E
r ot o M
C B A A
2 Roller
4 Roller
B C D E F F E
Re Ga s Re jec ts jec
3 Roller
Mill Door
D C B
A B
ts
Fan Power Consumption in VRM

High in comparison to Ball Mill Major Reason
Higher pressure drop
400 900 mm WG
Higher air flow rates
Pressure drop in a VRM

Ranges from 400 - 900 mm Wg Pressure drop
75% - Mill louvre 25% - Housing & classifier
Why High Pressure Drop ?

High louvre velocity : 55 85 m/sec Why high louvre velocity ?
Lift particles of higher sizes
Grinding table to separator
Reduction of louvre velocity

Reduction of mill - P Higher quantity of rejects at mill bottom
Mechanical Recirculation System

Rejects handled mechanically Recirculated back to mill through BE Tremendous reduction in pressure drop & energy consumption
Mechanical Recirculation
ESP
VRM VRM Fan
Louvre velocity vs. Mill power

Louvre velocity (m / sec) 75 Mill P (mm Wg) Reject rate (% of fled) Fan Power (units / ton) Mill power (units / ton) Total power 900 0 6.9 6.5 13.4 50 630 35 450
5 15% 150% 5.5 6.6 12.1 4.7 7.2 12.1*
* Includes power for mechanical recirculation

Louvre velocity How much reduction possible ?

Air flow through mill depends on
Louvre velocity Drying requirement Separator requirement
Reduction of louvre velocity to lower levels

Large material handling equipment Large mill housing
Leads to pre-separation Less stability & Table vibration
Optimum louvre velocities with mechanical recirculation : 45 55 m/sec

Reduce Recirculation Air in VRM

Recirculation air 60 kM3/Hr High recirculation air
High velocity At louvres High P High power consumption
10
Trial taken
Recirculation reduced by 20 kM3/HR RPM of class red. Same residue maintenance

R/M Fan power consumption reduced by 150 kW
Savings -
Rs 30 Lakhs
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Separators for VRMs

I stage II stage Static separator Dynamic conventional separator High efficiency separator
III stage -
High Efficiency Separators

Air requirement lower
High eff. - 0.6 0.8 kg matl / kg of air Conv. - 0.4 0.5 kg matl. / kg of air
Better separation efficiency Lower P across mill Higher output & lower specific energy consumption
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High efficiency Separator
Old Separator
Features of high efficiency Separator

Minimum pre-separation in mill housing Maximum separation in the separator Coarse return drops exactly in the centre of the table
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Features of high efficiency Separator

Benefits
Increase in output 10 to 30% Reduction in specific energy
1.5 to 3.5 units/ton
Very attractive financially
Replacement with High Efficiency Separator (Raw Mill)

Before Capacity Residue (90 ) Mill power (units / ton) Fan power (units / ton) Total Power After
250 TPH 290 TPH 11.5% 4.7 8.5 13.3

13.2% 4.1 6.2 10.3
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Effect of Roller to Table Dia

For the LM 38.4 the ratio between diameter for roller and table is 0.45, for the Ube LM 45.4 the ratio is 0.5, whereas for the LM 56.4 the ratio is 0.40.
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LM 38.4 LM 45.4(Ube) LM 56.4 Diameter of Grinding Table Diameter of Rollers Width of Rollers Kwh/ts, Mill Kwh/ts, Fan Residue (90/212 microns) Dust Load (g/cum) Delta P, Mill Vibration of Mill 3.80 m 1.70 m 0.67 m 6.31 6.23 12/0.8 610 83 3-5 4.50 m 2.24 m 0.85 m 5.99 5.51 11/0.8 630 56 2-4 5.60 m 2.24 m 0.85 m 7.00 7.00 11/0.9 595 87 5-8
Effect of Operating Pressure

Ube LM 40.4 Grinding Pressure kN/m2 Capacity Kwh/ts, Mill Vibration Delta P of Mill 650 290 9.0 4-5 54 662 295 9.0 4-5 53.5 675 300 9.0 4-5 53 687 305 9.0 4-5 52.5 700 310 9.0 4- 4.5 52
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Effect of Operating Pressure
10 % increase in Grinding pressure Capacity increase by 7% Mill drive SEC no change Fan power 0.5 kWh / MT reduction
Influence of Feed Size for an LM 40.4 Raw Mill

Max 90 mm Max 30 mm Capacity Kwh/ts, Mill Delta P, Mill Vibration 240 8.05 76 5-7
262 7.41 73 4-6
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High Level Control System for Mills

Conventional Open loop controls I Generation
P vs Feed controls
Latest control system

Min. 3 to 5% improvement Production & Energy More stable operation of VRM
High Level Control System for Mills

Latest control system
Feed Based on P, Load & Recirculation (B.E) Mill flow kept constant Mill Load, P, Recirculation load
Fineness predicted Separator speed varied
Prediction mechanism varied depending on actual fineness

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To Sum-Up
VRM Developing into an excellent choice
Raw mill, Coal, Cement & Slag
Further improvement opportunities

Mechanical recirculation High efficiency separators High level control system
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Vertical Roller Mill

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Vertical Roller Mill

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VERTICAL ROLLER MILLS

Confederation of Indian Industry